The proven strength and performance characteristics of precast concrete box culverts, together with their excellent service

life, make them ideal for a wide variety of civil engineering and construction applications. Box culvert sections can b e manufactured in a variety of shapes a n d sizes, offering exceptional versatility in the uses to which they can be applied. In addition to the more common use for diverting water courses, this versatili i s demonstrated i n b a l a n c i n g tan s, pedestrian subways, access shafts, service tunnels, sea outfalls, road crossings and many other situations where the w h o l e life costing consideration requires stren th, durability ond economy to e ! of paramount importance. Unlike other materials, such as steel, precast concrete box culverts do not require additional treotments to prolong their useful life or improve performance, their surfaces do not rust and the smooth internal finish of concrete ensures optimum flow of water through the box culvert. Precast concrete box culverts fulfil the current design life requirements for b u r i e d structures. The a b i l i t to provide many years of service wit the minimum of maintenance makes concrete box culverts the most costeffective means of diverting water courses, especially with the everpresent risk of corrosive elements in the water or soil. All association members offer the capability of individually designed structures for oll applications and loading conditions. This publication is o guide to the variety of applications in which precast concrete box culverts can be used, as well as providing information to assist i n their specification.

units allow for changes in direction and openings can be incorporated for inspection and pipe entry. Access to the longer runs should be restricted for safety.

ESCAPE TUNNELS
Box culverts can provide an effective underground means of escape for safe, sure and r a p i d evacuation from industrial and commercial premises, car parks, shopping centres, ond stadia.

BALANCING TANKS
The most economic way of providing inline or off-line storage of storm water i s the use of single or multiple runs of box culverts. Supplied complete with end walls, access and pipe entry openin s they are readily designed to car loadin from highways, car par s or any ot er overburden determined by their location.

SHAFTS
Box culverts ore used to provide vertical access shafts of large cross section and to resist very high horizontal pressures.

il

2i L

SERVICE TUNNELS
Box culverts are used to provide access

for underground services.

CATTLE CREEPS
Precast concrete box culvert units can provide durable construction and shelter for all conditions of exposure.

ROAD CROSSING
Box culverts ore designed to carry full highway looding for any application and offer a rapid means of construction.

TYPICAL FLOW CAPACITIES

1200

MULTI-CELL CONSTRUCTION
The largest flow capacity i n the minimum space with rectangular box sections laid side b side and only a nominal gap to a low for relative settlement.
600

1500

1800

9:s:
0.uu
0.98

8:s:
1.12

1:I
1.38

20 ,0
1.80

2400
I .B4

1.32

1.66

2.00
2.02 2.70

2.35
2.32 3.28

1000

:::: ::::
1500

1.72 2.31

., .

PIPE REPLACEMENT
Box culverts con be designed for as little a s 200mm cover and, where necessary, for no side pressure relief from the ground. No flow area i s wasted in arch profiles.

CULMRnNG O WAtERCOuRSES F
To permit the development of land crossed b y water courses, a w i d e range of sizes offers greater selection for economy and to ive the best flow capacity, even when t e gradient i s low and headroom or width i s restricted. lengths in excess of lOOOm have been culverted. Where appropriate topered

i: ,:

3.07
4.97

352 5.88

....

.
t,

91

PEDESTRIAN AND VEHICLE SUBWAYS

Sections are ovailable in suitable sizes for pedestrian subways and underpasses. larger sections w i l l accommodate cars and light commercial vehicles. Provision can be mode for lighting ond special finishes.

3.70
6.37

4.2L 7.58

i.
I
4.08

9.30

,, r

- : .... ........ ........ - . . . . . . . . . . . . . . . . . . .--- . . . . . . . . . . . . . . . . .

SEAOUTFAUS
Precast concrete box culvert units with increased cover to reinforcement and effective crack control provide the durability to resist the most extreme conditions of exposure.

CIRCULAR PIPE DISCHARGE RATE

Diameter Discharge rnm rate d / s

2 -

:I%

1050. 1200 1350 1500

1650 1800 1950 2100

1.00 1.42
1.93

2700

2.54
3.25 4.08

THRUST-BORED CULVERTS
Specially designed sections are o available f r installation by thrust-bore methods in suitable applications for trenchless construction.

5.03 6.11
8.65

2400

.........

--.......

..........-. .

.-

- -- .

. . .

CHOICE OF SECTION
Choice of section will be based on finding a flow capacity sufficient for the desi n rate of flow or a flow area to matc the required storage volume. Box ? l culverts may be desi ned with the height greater than l e width; the discharge rate of the section i s unchanged. Varying pro ortions of width to height are availaEle to meet restrictions on width, depth or headroom. The smallest width to height ratio allowed by the conditions of installation i s usually the most economic.

STANDARD SIZES
Standard sizes are based upon clear internal width and clear internal height. An extensive range of sizes is available with spans rangin from 1200 to 6OOOmm and heigtts from 600 to 3000mm. Not every manufacturer will necessarily offer all of this range. Some may offer an extended ran e or nonstandard sizes. A practico range of sections i s illustrated.

FLOW CAPACITY
Dischor e rates for box culverts in the range s own below are calculated for a gradient of 1 in 1000 in accordance with the Colebrook-White equation assuming the box culvert i s running full under uniform flow conditions. Comparable discharge rates for circular pipes are given. For an gradient between 1 in 1000 a n J 1 in 250, the gradient multiplier should be applied. A value of 0.3mm has been assumed for the roughness coefficient kS which depends upon the accuracy of laying and jointing in addition to the quality of the box culvert surface. Where a different value is required, the discharge rate at the appropriate gradient may be adjusted by use of the roughness multiplier. Thus for a 2 100 x 1 200mm section laid at o gradient of 1 in 600 and with an assumed roughness coefficient of 0.6mm, the discharge rate is given by 3.63 x 1.3 x 0.93 = 4.39m3/s. The flow capacity of a box culvert is determined b a number of different factors. In adJition to the gradient and roughness coefficient, the geometry of the inlet and outlet and the tailwater level can affect the mode of flow. This may prevent the box culvert from running full or under uniform flow conditions and the flow capacity will be lower than the full discharge rote.

9,

CORNER SPLAYS
Standard box culverts are provided with internal corner splays which are not standardised between association members. In this publication, to give a conservative value for flow area and discharge rate, sploy sizes have been taken as: 200 x 200mm for widths up to 3000mm 300 x 300mm for widths up to 4200mm 400 x 400mm far widths up to 600Omm

SPECIFICATION A N D DESIGN
Box culverts carrying highway loading to Department of Transport standards or other specified surfoce loading are usually designed to B S 5 4 0 0 or BS 8 1 10 and the Box Culvert Association Standard Specification: 1991 (available from the Association at a price of 3.00). The Box Culvert Association Specification covers materials, manufacture, tolerances, external loading, design a n d detailing standards. It provides a check list of information required from the specifier and provides for the issue of a compliance certificate.

JOlNTlNG
Joints are rebated and may be left open in certain cases but a preformed strip compressed within the joint i s commonly used. The strip should be applied to the box culvert just before it i s l a i d i n the trench. For further information on this and other aspects of layin see "A Guide to Site Practice" (Avafable free from the Association).

KEY T O TABLE Figures in Btu?= Flow area (m2)

Figures in BLACK= Discharge rate (m3/s)

GRADIENT MULTIPLIER
Gradient 1 in 1000 1 in 800 1 in 700 1 in 600 1 in 500 1 in 400 1 in 300 1 in 250 Multiplier

All dimensions in mm.

2700

1 .o 1.1

ROUGHNESS MULTIPLIER
Roughness Multiplier Coefficient ks

.:. ... .
3.78
L .:: 4.94

3000
4.28

1.2 1.3
1.4 1.6 1.8

3300
5 60
0 11

3600
8.76

42W
J'.

2.0

0.06 0.15 0.3 0.6 1.5

5400
?.. , 19.70

1.1 1 1.05 1 .oo

0.93 0.85

s.80

7.73

... ....

8.52

0.46

...

i !,:

it37

4800

....
0.77

$.Si

...
11.08 12.33
14 BJ

17.13

....
I4

id:&

.....

12.38

. .... .

13.78

. . .. .

...
15%

I8 54

21.50

24 75

. .
i2.93 I4.b
18 57

18.49

22.38

...... ....

. .~
26.08

.. .....
30.07

%.m

.:.:

...
15.10

17.31

:. ,.

...
1:9.U

. .
21.73 26 36

....
30 0
35 00
4041

....
:t

1988

25.05

30.45

35.73

41.32

:.: .....
,

. , :.
W,G

.-._ .................

"

._

..

Comprising the United Kingdom's leading manufacturers of precast concrete box culverts, the Box Culvert Association is actively involved in research and development programmes aimed at extending the application of box culverts and advancing installation techniques to speed construction and maximise efficiency. The Association produces a number of publicotions to assist in the correct specification and installation of precast concrete box culverts. These include: Applications Guide Guide to Site Practice Box Culvert Association Standard Specification:1991 Members o the Box Culvert Association: f

Albion Concrete Products Ltd.

Pipe House Wharf, Modo Road, Swansea, West Glamorgan SA1 1TD Tel: 01792 655968 Fox: 01792 644461

F C Precast Concrete Ltd.

Alfreton Road, Derby DE2 1 4BN Tel: 01332 364314 Fox: 01332 372208

Milton Pipes Ltd.

Milton Regis, Sittingbourne, Kent ME10 2QF Tel: 01795 425191 Fox: 01795 478232

Tarmac Precast Concrete Ltd.

Tallington, Stamford, Lincs PE9 4 L R Tel: 01778 381000 Fox: 01778 348041

ASSOCIATION
Box Culvert Association 60 Charles Street Leicester LE 1 1FB Tel: 01 16 253 6161 Fox: 01 16 251 4568 e mail: briprecast Q aol.com
January 1997 edition. Designed and published by the Box Culvert Association. A Product Association of the British Precast Concrete Federation Although the Box Culvert Association makes every endeavour to ensure that any advice, recommendation or information it may give is accurate, no liability of any kind (including liability for negligence) i s accepted in this respect by the Association, its servants or agents.

conerete

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